Apparatus and method for setting yarn and for crimping and setting yarn



y 1962 M. E. TAGER ETAL 3,044,145

APPARATUS AND METHOD FOR SETTING YARN AND FOR CRIMPING AND SETTING YARNFiled Oct. 31, 1958 4 Sheets-Sheet l 1: jig?) INVENTORS T 1H1 fax/EFL?dad/#4717 BMW/i6 82.

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By Z TTORNEYS.

July 17, 1962 M. E. TAGER ETAL 3,044,145

APPARATUS AND METHOD FOR SETTING YARN AND FOR CRIMPING AND SETTING YARNFiled Oct. 31, 1958 4 Sheets-Sheet 2 A TTORNEYS.

July 17, 1962 M. E. TAGER ETAL 3,044,145

APPARATUS AND METHOD FOR SETTING YARN AND FOR CRIMPING AND SETTING YARNFiled Oct. 51, 1958 4 Sheets-Sheet 4 A TTORNEYS United States Thisinvention relates to textiles, and more particularly concerns apparatusand method for setting yarn, and for crimping and setting yarn.

In the heat setting of yarn made, for example, of continuous filamentnylon, the yarn is passed through a heat ing zone in which the yarn isbrought to a predetermined maximum temperature. It is desirable. toextrude the yarn from a crimper and to set it in a continuous manner,and to set a multiplicity of yarn ends at the same time. However,machinery such as crimpers are subject to failure, and such failurecauses a stoppage of the yarn travelling through the heating Zone. Thisstoppage of the yarn subjects the yarn to variations in temperaturesince some portions of the yarn remain in the heating zone longer thanother portions, which causes variations in the dye index of the yarn andresults in variations in shading of the color of the yarn when dyed.This variation in shading is objectionable.

Accordingly, it is an object of this invention to crimp and to heat-setyarn at a uniform temperature.

It is another object of this invention to give the yarn a uniform dyeindex so that When dyed the yarn is a uniform shade.

It is another object of this invention to heat-set yarn by uniformlyexposing the yarn to an electronic field, and to heat-set a multiplicityof ends of yarn made of continuous filament nylon or the like.

It is another object of this invention to continuously crimp and setfilament yarn. It is another object to avoid over-heating the yarn incase a stoppage occurs in the advancement of the yarn through thesetting mechanism.

Other objects and advantages of this invention, including its simplicityand economy, as well as the ease with which it may be used with existingequipment, will further 4 become apparent hereinafter and in thedrawings, in which:

FIG. 1 is an overall View in side elevation of another embodiment ofthis invention;

FIG. 2 is a diagrammatic view of controls for erase plates whichconstitute an element of the embodiment of FIG. 1;

FIGS. -312 represent partial views illustrating the operation of theerase plates of the embodiment of FIG. 1; and

FIG. 13 is an overall view in side elevation of one specific embodimentof apparatus constructed in accordance with this invention.

In describing the preferred embodiments of the invention illustrated inthe drawings, specific terminology will be resorted to for the sake ofclarity. However, it is not intended to be limited to the specific termsso selected, and it is to be understood that each specific term includesall technical equivalents which operate in a similar manner toaccomplish a similar purpose.

Turning now to the specific embodiment of the invention selected forillustration in FIG. 13, there is shown a crimper mechanism 1, a settingmechanism 2 including electrodes 8 and 4 which form therebetween aheating zone 5, and drag rolls 6 which operate together with co nveyorbelts 7, 8 to advance yarn 9 from the crimper mechanism 1 through thesetting mechanism 2.

"atent be The passage of yarn 9 through the mechanism shown and throughother textile machines (not shown) is as follows. Yarn 9 enters crimpermechanism 1 as a sheet composed of a multiplicity of yarn ends. Yam 9 iscrimped in crimper mechanism 1 and extruded in the form of a bat and iscarried by conveyor belts 7, 8 through the electronic field which iscreated between electrodes 3, 4 which are connected to a source of highfrequency electrical energy. As yarn 9 enters the electronic field, thehigh frequency causes an internal heating to take place within the yarnso that the temperature within the yarn rises as it moves through theelectronic field until it reaches approximately 400 F., at whichtemperature it passes out of the electronic field and is carried bybelts 'i, 8 to the drag rolls 6. Drag rolls 6 break the bat down into acontinuous sheet which is taken up by a warper or similar device (notshown). The warper is running at approximately the same speed ascrimping mechanism 1 and stretches yarn 9 to the extent that it maysplit by means of a comb (not shown) just prior to being wound on beams(not shown). From the beams, yarn 9 may be wound on individual cones orspools, or it may be plied and then wound on individual cones.

Since stoppages in the crimping process will inevitably occur due tobroken or tangled ends of yarn, provision is made to insure that theyarn 9 is sufiiciently heated to set the crimp, and also to insure thatexcessive heating does not occur. To accomplish this, an erase plate 10is provided which is interposed between yarn 9 and electrode 3 whenstoppages of yarn movement occurs. The crimp can be properly set only byclosely controlling the temperature to which yarn 9 is subjected, andalso by controlling the time during which yarn 9 is subjected to thattemperature. The speed at which yarn 9 advances through settingmechanism 2 must be carefully controlled, and should stoppage occur, theheat applied to yarn 9 must be out Oh at the same time as it would havebeen cut off had it continued its movement. This is accomplished bymoving erase plate 10 between electrode 3 and yarn 9 when the yarn 9 hasstopped, and moving erase plate 10 at the same speed as the yarn 9 hadpreviously been moving.

Erase plate 10 thus travels in the direction opposite to yarn traveluntil it reaches its extreme left hand position at which point itcompletely cuts off electrode 3 from yarn 9. After the fault has beencorrected, the yarn resumes its travel and erase plate 10 travels withyarn 9 to resume its normal operating position as shown in FIG. 13.

It will be evident that crimper mechanism 1 includes drive motor 11which drives crimper rolls 12, and a crimper box 13 having an adjustablegate 14.

The yarn 9 which is extruded from crimper mecha nism 1 is picked up andadvanced by conveyor belts 7, 8 which are also driven by drive motor 11.Belts 7, 8 are provided with quilted layers 15, 16 which affordsuflicient insulation to prevent loss of heat from yarn 9. Settingmechanism 2 also includes limit switches 17, 18 for erase plate 10.Erase plate 10 is provided with a rack 19 which is driven by pinion 20.

Turning now to the specific embodiment of the invention selected forillustration in FIGS. l-12, there is shown a crimper mechanism 21, asetting mechanism 22 including electrodes 23 and 24 which formtherebetween a heating Zone 25, and drag rolls 26 which operate togetherwith conveyor belts 27, 28 to advance yarn 31 from the crimper mechanism21 through the setting mechanism 22.

The passage of yarn 31 through the mechanism shown and through othertextile machines (not shown) is as follows. Yarn 31 enters crimpermechanism 21 as a sheet composed of a multiplicity of yarn ends. Yarn 31Patented July 17, 1962' is crimped in crimper mechanism 21 and extrudedin the form of a bat and is carried by conveyor belts 27, 28 through theelectronic field which is created between electrodes 23, 24 which areconnected to a source of high frequency electrical energy. As yarn 31enters the elec tronic field, the high frequency causes an internalheating to take place within the yarn so that the temperature within theyarn rises as it moves through the electronic field until it reachesapproximately 400 F., at which temperature it passes out of theelectronic field and is carried by belts 27, 28 to the drag rolls 26.Drag rolls break the bat down into a continuous sheet which is taken upby a warper or similar device (not shown). The warper is running atapproximately the same speed as crimping mechanism 21 and stretches yarn'31 to the extent that it may be split by means of a comb (not shown)just prior to being wound on beams (not shown). From the beams, yarn 31may be wound on individual cones or spools, or it may be plied and thenwound on individual cones.

Since stoppages in the crimping process will inevitably occur due tobroken or tangled ends of yarn, provision is made to insure that theyarn 31 is sufiiciently heated to set the crimp, and also to insure thatexcessive heating does not occur. To accomplish this, run erase plate 32and stop erase plate 33 are provided. The crimp can be properly set onlyby closely controlling the temperature to which yarn 31 is subjected,and also by controlling the time during which yarn 31 is subiected tothat temperature. This means that the speed at which the yarn 3iadvances through setting mechanism 22 must be carefully controlled, andshould stoppage occur, the heat applied to yarn 31 must be cut off atthe same time as it would have been cut ott had it continued itsmovement. This is accomplished by interposing erase plates 32, 33between the yarn and electrode 23.

Detailed Description Crimper mechanism 21 includes drive motor 35 whichdrives crimper rolls 36, and a crimper box 37 having an adjustable gate38.

The yarn 31 which is extruded from crimper mechanism 21 is picked up andadvanced by conveyor belts 2'7, 28 which are also driven by drive motor35. Belts 27, 28 are provided with quilted layers 41, 42 which affordsufficient insulation to prevent loss of heat from yarn 31. Settingmechanism 22 (referring to FIG. 1) also includes limit switches 43, 44for stop erase plate 33, and limit switches 45, 46 for run erase plate32. Stop erase plate 33 is provided with a rack 47 which is driven bypinion 48, and run erase plate 32 is provided with a rack 51 which isdriven by pinion 52.

The distance between edge 53 of run erase plate 32 and edge 54 of stoperase plate 33 (with plates 32 and 33 positioned as shown in FIGS. 3 and1), represents the normal heating length (NHL) through which the yarn'31 travels within heating zone 25 in order to be raised to the properheating temperature. FIGS. 1, 3 not only illustrate the normal heatinglength, but also illustrate the normal heating position of plates 32,33, with stop erase plate edge 54 positioned below exit edge 55 ofelectrode 23, and run erase plate edge 53 positioned half-way betweenentrance edge 56 and exit edge 55 of electrode 23.

Referring now to FIG. 2, there is shown a start-stop switch 57, drivemotor 35, limit switch 45 with its contact 58, limit switch 46 with itscontacts 61 and 62, limit switch 43 with its contacts 63 and 64, limitswitch 44 with its contact 65, solenoid clutches 66, and 67, reversiblemotor 68, a high frequency generator 71, and electrical leads which arearranged to connect the various components in an electrical circuit.Start-stop switch 57 is provided with contact 72 and terminals 73a and7315. Also provided are contacts 74, 75, trip arm 76 attached to theunderside of stop erase plate 33, and actuating arm A. 77 which isoperated by trip arm 76 to open contact 74 and close contact 75.

Operation of Erase Plates 32, 33

Since stoppages in the crimping process will inevitably occur due tobroken or tangled ends of yarn, provision is made to insure that yarn 31is sufiiciently heated to set the crimp, and to insure that yarn 31 isnot subjected to excessive heat. To accomplish this, the electronicfield or heating zone 25 is equipped with erase plates 32, 33. Since thecrimp can be set properly only by closely controlling the temperature towhich yarn 31 is subjected and the time during which yarn 31 issubjected to that temperature, yarn 31 is advanced through heating Zone25 at a constant speed, and the speed is controlled very accurately.Should a stoppage occur, erase plates 32, 33 operate to cut off the heatand do so by moving through the heating zone in a direction opposite tothe direction of yarn travel, and moving at the same speed as the yarn,had there been no stoppage.

In order to provide for erasing the heat of the electronic field underall conditions of operation, there are provided two erase plates, thestop erase plate 33 which enters heating zone 25 from its exit end, andrun erase plate 32 which enters the heating zone 25 from its entranceend.

Under normal conditions, as is shown in FIG. 3, stop erase plate 33 isstationary and is positioned just outside the exit end of heating zone25, and run erase plate 32 is positioned a normal heating length awayfrom stop erase 33 so as to block off half of the electronic fieldbetween electrodes 23 and 24. Yarn 31 is advancing through the normalheating length at a predetermined constant speed and is heated to apredetermined maximum temperature, for example 400 F., to set thecrimped yarn. If a stoppage of yarn 31 should occur, both plates 32, 33immediately start moving in the direction opposite to the direction ofyarn travel as is shown in FIGS. 4 and 5, Should the stoppage continuelong enough, run erase plate 32 completes its travel and stops at theposition shown in FIG 5, with plate 33 continuing its advance as shownin FIG. 6. Notice that the distance between plates 32, 33 is now lessthan the normal heating length. With the stoppage continuing, plate 33advances to the position shown in FIG. 7, which deenergizes electrodes23, 24.

The fault having been fixed, yarn 31 resumes its travel as is shown inFIG. 8, and plate 33 travels With it to open the distance between plates32, 33 to the normal heating length as is shown in FIG. 9. At this pointplate 33 stops, and plate 32 starts to advance with yarn 31 and passesthrough the position shown in FIG. 10 to the position shown in FIG. 11.Plate 32 now has reached its normal position and stops there, and plate33 resumes its travel with yarn 31 and stops at its normal position asshown in FIG. 12. Notice that FIG. 12 is the same as FIG. 3, the cyclehas been completed.

Should the stoppage be corrected while plates 32, 33 are in any positionbetween FIG. 4 and FIG. 5, plates 32, 33 stop and remain stationary,thus providing a normal heating length for the advancing yarn.

Should the stoppage be corrected after run erase plate 32 has completedits travel but before stop erase plate 33 has completed its travel (forexample, the situation shown in FIG. 6), stop erase plate 33 immediatelystops and run erase plate 32 advances toward stop erase plate 33 untiledges 53 and 54 are aligned, whereupon run erase plate 32 stops and stoperase plate 33 moves along with the yarn until it is separated from runerase plate 32 by the normal heating length. Then stop erase plate 33stops thereby providing a normal heating length for the advancing yarn.Notice that the normal heating length is provided even though stop eraseplate 33 is not positioned in the normal heating position of FIG. 3, butis instead positioned somewhere between that position and the positionof FIG. 5.

Relating FIGS. 3-12 With the Control Circuit of FIG. 2

With the erase plates 32, 33, positioned as shown in FIG. 3, in thecontrol mechanism of FIG. 2, drive motor 35 is operating, reversiblemotor 68 is not energized, clutches 66 and 67 are disengaged, highfrequency generator 71 is operating, and all contacts are closed except73b, 62, 75, and 65.

With conditions as shown in FIG. 4, the start of the yarn stoppage,motor 35 is cut off, motor 63 is running, clutches 66, 67 are engaged,generator 71 is operating, and all contacts are closed except contacts73a, 62, 75, and 65.

With the stoppage continuing as shown in FIG. 5, drive motor 35 isde-energized, motor 68 is running, clutch 66 is disengaged, clutch 67 isengaged, generator 71 is operating, contacts 73b, 62, 74, 63, 64, and 65are closed, and contacts 73a, 58, 61, and 75 are open.

With conditions as shown in FIG. 7, motor 35 is cut off, motor 68 iscutoff, clutches 66, 67 are disengaged, generator 71 is cut off,cont-acts 73b, '62, 74 and 65 are closed, and contacts 73a, 58, 63, 64,61, 75 are open.

With conditions as shown in FIG. 8, motor 35 is running, motor 68 isrunning, but is rotating in an opposite sense, generator 71'isoperating, clutch 66 is disengaged, clutch 67 is engaged, contacts 73a,62, 63, 64, 74, and 65 are closed, and contacts 73b, 61, 75, are open.

With conditions as shown in FIG. 9, motor 35 is running, motor 68 isrunning, clutch 66 is engaged, clutch 67 is disengaged, generator 71 isoperating, contacts 73a, 58, 63, 64, 62, 75, and 65 are closed, andcontacts 73b, 61, 74, are open.

With conditions as shown in FIG. 10, motor 35 is running, motor 68 isrunning, clutch solenoid 66 is engaged, clutch solenoid 67 isdisengaged, generator 71 is operating, contacts 73a, 58, 63, 64, 62, and75 are closed, and contacts 73b, 61, 65 and 74 are open.

With conditions as shown in FIG. 11, motor 35 is operating, motor 68 isoperating, clutch 66 is disengaged, clutch 67 is engaged, generator 71is operating, contacts 73a, 58, 61, 63, 64, and 75 are closed, andcontacts 73b, 62, 65 and 74 are open.

With conditions as shown in FIG. 12, the control elements of FIG. 2 arein the same condition as described in connection with FIG. 3.

Setting mechanism 22 with its erase plates 32 and 33 insures that yarn31 is set at a uniform temperature, and gives the yam a uniform dyeindex so that when dyed it is a uniform shade.

The apparatus of this invention provides for continuous and uniformheat-setting of a multiplicity of ends of yarn made of continuousfilament nylon or the like, and does so by subjecting the yarn touniform exposure in an electronic field. Over-heating of the yarn duringa stoppage of its advancement through setting mechanism 22-is preventedby providing erase plates 32 and 33 and their controls.

It is to be understood that the form of the invention herein shown anddescribed is to be taken as a preferred embodiment. Various changes maybe made in the shape, size and arrangement of parts. Equivalent elementsmay be substituted for those described herein, parts may be reversed,and certain features of the invention may be utilized independently ofthe use of other features, all without departing from the spirit of theinvention or the scope of the subjoined claims. It is also to beunderstood that the term yarn, as used in the subjoined claims, includessingle ends of yarn, a tow of yarn, crimped and uncrimped yarn, yarnmade of nylon, and, in general, any elongated object.

Having thus described our invention, we claim:

1. Apparatus for heat setting a yarn, comprising a pair of electrodeswhich generate heat and which are spaced apart to form a heating zonetherebetween, means for transporting said yarn through said heating zoneat a predetermined rate of speed to heat said yarn to varioustemperatures up to a predetermined maximum temperature, and shieldingmeans for shielding said yarn from said heat after said yarn has reachedsaid predetermined maximum temperature, said shielding means including astop erase plate and control means for moving the plate at the speed ofyarn travel in the direction opposite that of yarn travelaf-ter the yarnhas stopped in order to cut off the yarn from heat as the yarn reachessaid predetermined maximum temperature.

2. The apparatus for heat setting yarn defined in claim 1, wherein saidshielding means is also provided with a run erase plate which isnormally positioned a predetermined normal heating length away from saidstop erase plate, means for stopping said run erase plate and forcontinuing the movement of said stop erase plate thereby to decrease thedistance between said erase plates, and, upon the yarn resuming itstravel with the distance between said erase platesles-s than said normalheating length, means for stopping said stop erase plate and for movingsaid run erase plate toward said stop erase plate.

3. Apparatus for heat setting yarn, comprising a pair of electrodeswhich generate heat and which are spaced apart to form a heating zonetherebetween, means for transporting said yarn through said heating zoneat a predetermined rate of speed to heat said yarn to varioustemerature's up to a predetermined maximum temperature, and shieldingmeans for shielding said yarn from said heat in case of stoppage of yarntravel after said yarn has reached said predetermined temperature,wherein said shielding means includes a run erase plate and a stop eraseplate normally positioned a normal heating length apart; and erase platecontrol means for moving said plates, upon the yarn stopping its travel,at yarn speed in the direction opposite yarn travel thereby cutting offthe heat to the stopped yarn after it has reached said predeterminedtemperature; means for stopping said run erase plate upon reaching alimit and for continuing the movement of said stop erase plate forcontinuing to cut-off said heat from the yarn as the yarn reaches saidpredetermined maximum temperature, and means, upon the yarn resuming itstravel, for again spacing said plates a normal heating length apart.

4. In an apparatus for crimping and heat-setting yarn, including crimpermeans for crimping the yarn and heatsetting means for subjecting thecrimped yarn to heat of a predetermined temperature, the improvementwhich comprises, means for transporting the yarn at a substantiallyconstant rate through said setting means, and shield ing means connectedto said setting means and disposed adjacent thereto for shielding saidyarn from heat, said shielding means being arranged to respond to astoppage of said yarn to move between said yarns and the source of saidheat so that said yarn receives a uniform application of heat throughoutthe length thereof passing through said setting means.

5. Apparatusfor heat-setting yarn, comprising a pair of electrodes whichgenerate heat and are spaced apart to form a heating zone therebetween,means for transporting said yarn through said heating zone at apredetermined rate of speed to heat said yarn to various temperatures upto a predetermined maximum temperature, and shielding means forshielding said yarn from said heat after said yarn has reached saidpredetermined temperature and arranged to move between said electrodesand said yarn so that said yarn receives a uniform application of heatthroughout the length thereof passing through said apparatus.

6. Apparatus for heat-setting a multiplicity of ends of yarn made ofcontinuous filament nylon or the like, comprising a pair of electrodeswhich generate heat and which are spaced apart to form a heating zonetherebetween, conveyor means for transporting said yarn through saidheating done at a predetermined, constant speed to heat said yarn tovarious temperatures up to a predetermined maximum temperature, andshielding means for shielding said yarn from said heat after said yarnhas reached said predetermined temperature, said shielding means beingarranged to move between said electrodes and said yarn Whenever saidyarn has stopped in its travel through said heating zone so that saidyarn receives a uniform application of heat throughout the lengththereof passing through said setting means.

References Qited in the file of this patent UNITED STATES PATENTS BakerAug. 31, 1948 Ferier Jan. 26, 1954 Walter Nov. 29, 1955 Herele et a1,Jan. 31, 1956 Goodhue Aug. 14, 1956 Lessig Aug. 12, 1958 Sellers Feb.24, 1959

